EUV lithography has already introduced in high volume manufacturing and continuous improvements has allowed to resolve pitch 24nm line and space (L/S), pitch 32nm contact hole and pillar pattern with single exposure at even numerical aperture (NA) 0.33. However, pattern roughness, local critical dimension uniformity (LCDU) and process related defects are still major challenges with decreasing critical dimensions (CD). Pitch downscaling also require the use of thinner photoresist mask to prevent pattern collapse from high aspect ratios. Thinner photoresist mask is challenging for pattern transfer because the resist “etch budget” is becoming too small to prevent pattern break during plasma etch transfer. It is required to investigate a co-optimization of lithography processes, underlayers and etch processes to further EUV patterning extension. In this paper, our latest developed process solutions to extend the limits of EUV patterning will be reported. The advanced performance for metal oxide resists (MOR) will be introduced, with a focus on defect mitigation, dose reduction strategies and CD stability.
As the semiconductor industry continues to push the limits of integrated circuit fabrication, reliance on extreme ultraviolet lithography (EUVL) has increased. Additionally, it has become clear that new techniques and methods are needed to mitigate pattern defectivity and roughness at lithography and etch process and eliminate film-related defects. These approaches require improvements to the process chemicals and the lithography process equipment to achieve finer patterns. ESPERTTM (Enhanced Sensitivity develoPER TechnologyTM) technique has been developed and optimized to fulfil this novel development need. ESPERTTM has demonstrated a capability that can enhance the developing contrast between the EUV exposed and unexposed areas. This paper reviews 23 nm pitch line and space and sub-40 nm pitch pillars which were realized by optimized illuminators with 0.33 NA single exposure, and we will show how ESPERTTM helped improve the minimum critical dimension size, defectivity, roughness and electrical yield at the finer patterns.
Recent advancements in extreme ultraviolet (EUV) lithography have greatly enhanced the manufacturing of fine semiconductor nodes in high volume production (HVM). With the introduction of high NA (numerical aperture) EUV, further miniaturization is expected, and it is necessary to develop lithography technology to accommodate this. Chemically amplified resist (CAR) is widely used in HVM due to their stability and advantages as metal–free resists, and adapting CAR to the High–NA EUV era has important implications. Achieving high resolution in EUV involves a trade–off between resolution, line width roughness (LWR), and sensitivity. Reducing roughness is especially important because roughness can cause pattern defects. This paper aims to reduce CAR roughness and improve the trade–off. We investigated the reduction of roughness through a post–development treatment applied to EUV–exposed patterns. To examine the influence of this post–development treatment, we performed a power spectral density (PSD) analysis of LWR. Additionally, we compared the cross–sectional shape of resist patterns before and after treatment to understand the reactions occurring within the resist. The results showed that the LWR decreased by 13.1% for 44nm line/space (L/S) pitch and 4.0% for 28nm L/S pitch after the post–development treatment. Of particular interest, the use of additional processing demonstrated the potential to reduce low–frequency roughness, which is normally very challenging. These results show the potential for the application of CAR in next–generation lithography.
One of the key steps in the pattern formation chain of extreme ultraviolet (EUV) lithography is the development process to resolve the resist pattern after EUV exposure. The traditional development process might be insufficient to achieve the requirements of ultra-high-resolution features with low defect levels. The aim of this paper is to establish a process to achieve a good roughness, a low defectivity at a low EUV dose, and capability for extremely-high-resolution for high numerical aperture (NA) and hyper-NA EUV lithography. A new development method named ESPERT™ (Enhanced Sensitivity develoPER Technology™) has been introduced to improve the performance of metal oxide-resists (MOR). ESPERT™ as a chemical super resolution technique effectively apodized the MOR chemical image, improving chemical gradient (higher exposure latitude (EL)) and reducing scums (fewer bridge defects). This new development method can also keep the resist profile vertical to mitigate the break defects. The performances of the conventional development and ESPERT™ were evaluated and compared using 0.33 NA EUV, 0.5 NA EUV, and electron beam (EB) exposures, for all line-space (LS), contact hole (CH), and pillar (PL) patterns. Using 0.33 NA EUV scanners on LS patterns, both bridge and break defects were confirmed to be reduced for all 32-nm-pitch, 28-nm-pitch, 26-nm-pitch LS patterns while reducing the EUV dose to size (DtS). In the electrical yield (1 meter length) test of breaks/bridges of 26-nm pitch structures, ESPERT™ reduced EUV dose while its combo yield was almost 100% over a wide dose range of 20mJ/cm². For CH patterns, in the case of 32-nm-pitch AEI (after etch inspection), EL was increased 7.5% up to 22.5%, while failure free latitude (FFL) was widened from 1-nm to 4-nm. A 16-nm-pitch LS pattern was successfully printed with 0.5 NA tool, while a 16-nm-pitch PL and an 18-nm-pitch CH patterns were also achieved with an EB lithography by ESPERT™. With ESPERT™, there was no pillar collapse observed for 12-nm half-pitch PL by 0.5 NA and 8-nm half-pitch PL by EB. With all the advantages of having a high exposure sensitivity, a low defectivity, and an extremely-high-resolution capability, this advanced development method is expected be a solution for high-NA EUV towards hyper-NA EUV lithography.
As the semiconductor industry continues to push the limits of integrated circuit fabrication, reliance on extreme ultraviolet lithography (EUVL) has increased. Additionally, it has become clear that new techniques and methods are needed to mitigate pattern defectivity and roughness after lithography and etch processes and eliminate film-related defects. These approaches require further improvements to the process chemicals and the lithography process equipment to achieve finer patterns. The ESPERTTM (Enhanced Sensitivity develoPER TechnologyTM) technique has been developed and optimized to fulfil this novel development need. The ESPERTTM has demonstrated a capability that can enhance the developing contrast between the EUV exposed and unexposed areas. This paper reviews that 23 nm pitch line and space and sub-40 nm pitch pillars patterns were realized by high NILS illuminations with 0.33 NA single exposure, and we will show the ESPERTTM helped reduce the minimum critical dimension size, defectivity and roughness at the finer patterns.
Extreme ultraviolet (EUV) lithography has already introduced in high volume manufacturing and continuous improvements has allowed to resolve pitch 24 nm line and space (L/S), pitch 32 nm contact hole and pillar pattern with single exposure at even numerical aperture (NA) 0.33. However, pattern roughness, local critical dimension uniformity (LCDU) and process related defects are still major challenges with decreasing critical dimensions (CD). Pitch downscaling also require the use of thinner photoresist mask to prevent pattern collapse from high aspect ratios. Thinner photoresist mask is challenging for pattern transfer because the resist “etch budget” is becoming too small to prevent pattern break during plasma etch transfer. It is required to investigate a co-optimization of lithography processes, underlayers and etch processes to further EUV patterning extension. In this paper our latest developed technology and process solutions to extend the limits of EUV patterning will be report.
One of the key steps in the pattern formation chain of extreme ultraviolet (EUV) lithography is the development process to resolve the resist pattern after EUV exposure. A simple traditional development process might be insufficient to clear the holes in contact-hole (CH) patterns and often causes missing hole defects around target-CD. In prior papers, a new development method named ESPERT™ (Enhanced Sensitivity develoPER Technology™) has been introduced to improve the performance of metal oxide-resists (MOR) for line/space (L/S) and pillar patterns. ESPERT™ as a chemical super resolution technique effectively apodized the MOR chemical image, improving chemical gradient and reducing scums. In this work, this development technique was optimised for CH patterns to reduce both the local CD uniformity (LCDU) and to reduce the levels of missing contact holes at a lower exposure dose. This is made possible thanks to the capability of the updated version of ESPERT™ that can effectively remove the scums (resist residues) inside CH to extend the missing hole defect margins. The high development contrast of the new development technique results also in a much higher exposure latitude. Using 0.33 NA EUV scanners on 36-nmpitch hexagonal patterns, the new development enhanced exposure latitude (EL), failure free latitude (FFL), and failure free dose ranges at both ADI (after development inspection) and AEI (after etch inspection) for two diverse types of MORs. For instance, in the case of the reference MOR developed by ESPERT™, CHs were nicely transferred to a TiN layer, even for small CD holes of 14.7 nm. If compared to the data by conventional development, using the new method, the EL was increased from 16.0% to 49.1%, the FFL was extended from 2 nm to 6 nm, and the failure free dose range was increased from 13.3% to 72.2%. It was also possible to have EUV dose-to-size (DtS) of 28 mJ/cm² with EL of 49.9% at ADI, using the new development. With all those advantages, this new development method is expected to be the solution for CH pattern formation of negative tone MORs in EUV lithography.
High-NA EUV lithography is currently under development to keep up with device node scaling with smaller feature sizes. In this paper, the most recent advances in EUV patterning using metal oxide resists (MOR) and chemically amplified resists (CAR) are discussed. A newly developed resist development method (ESPERT™) was examined on MOR with 24 nm pitch line and space (L/S) patterns and 32 nm pitch pillars for preparation of high-NA EUV patterning. The patterning results showed improved sensitivity and pattern collapse margin. CAR contact hole patterning at 28 nm pitch was also examined by stochastic lithography simulation. The simulation results indicate that resist film thickness needs to be optimized for target pitches.
One of the key steps in the pattern formation chain of (extreme ultraviolet) EUV lithography is the development process to resolve the resist pattern after EUV exposure. A simple traditional development process might not be sufficient to achieve the requirements of an ultra-high-resolution feature with low defect levels in high numerical aperture (NA) EUV lithography. In our previous literature, a new development method named ESPERTTM (Enhanced Sensitivity develoPER TechnologyTM) has been introduced to improve the performance of metal oxide resists (MOR) for 0.33 NA EUV lithography by breaking the dose-roughness trade-off. In this work, this development technique was optimised for high-NA lithography to not only keep the advantages of previous ESPERTTM version, but also reduce the defect levels at a higher EUV sensitivity. This is made possible thanks to the capability of the new version of ESPERTTM that can easily remove the residue (undeveloped resist) at low exposure dose area to enhance the developing contrast. Using 0.33 NA EUV scanners at imec on 16-nm half-pitch (HP) line/space (L/S) patterns, with the new development method, EUV dose-to-size (DtS) was reduced roughly 16%, and total after-development-inspection (ADI) defects was reduced by a factor of approximately 7, simultaneously. In another condition, DtS was reduced from 44.2 to 28.4 mJ/cm² (an improvement of 36%), while the number of after-etch-inspection (AEI) single-bridge defects was reduced by half, simultaneously. Using the 0.5 NA exposure tool at Lawrence Berkeley National Laboratory with this new development method, the exposure sensitivity and line-width-roughness (LWR) were both improved by 30% and 21%, respectively. An 8-nm-HP L/S pattern was also successfully printed by this high NA tool. Using a 150 kV electron-beam (EB) lithography system, a 12-nm-HP of pillars was successfully printed on a 22-nm-thick MOR resist with ESPERTTM. With all the advantages of having a high exposure sensitivity, a low defectivity, and an ultra-high-resolution capability, this new development method is expected to be a solution for high-NA EUV lithography.
Resolution, line edge roughness (LER) and sensitivity (RLS) and defectivity are the well-known critical issues of extreme ultraviolet (EUV) lithography. To break the RLS triangle, metal oxide resist (MOR) is a promising candidate. However, further improvement of MOR process is required for high volume manufacturing to maintain low defectivity. In this paper, conventional and new processes for MOR pitch 32 nm line and space (L/S) and 36 nm pillar patterns was investigated. This new process was able to perform good sensitivity without degrading roughness. In addition, further optimization for underlayer and developer process could mitigate pattern collapses. MOR treatment was evaluated as another technique for roughness improvement. At last, bottom scum defect would be reduced by new process.
In this study we examine several innovations. In lithography, we introduce our latest progress on metal oxide resist (MOR) to extend defectivity window, improve photo-speed, and wafer uniformity control by leveraging new resist development techniques.
On the plasma etch front, we focus on plasma-resist interactions and the impact of the pattern transfer process. Gas chemistry and plasma characteristics can modulate resist rectification, leading to a widening of the defectivity window and smoothing of pattern roughness. Especially, when reducing line-space pattern defectivity, correlations between plasma characteristics and microbridge defect numbers point to a proper process regime for patterning in the sub 30nm pitch era.
As the semiconductor industry continues to push the limits of integrated circuit fabrication, reliance on extreme ultraviolet lithography (EUVL) has increased. New techniques and methods are needed to mitigate pattern defectivity and roughness using both lithography and etch processes to eliminate film-related defects. These approaches require further improvements to the process chemicals and the lithography process equipment to achieve finer patterns. Additionally, underlayers and resist optimization play a significant role in resist pattern fidelity. This paper reviews the ongoing progress in coater/developer processes that are required to enable EUV patterning by using chemically amplified and metal oxide resists. We will discuss several new techniques for pattern defectivity, roughness, and EUV dose- to- size reduction using coater/developer processes. In addition, we will review our study with various underlayers to enable smaller minimum critical dimension size.
In this talk we present core technology solutions for EUV Patterning and co-optimization between EUV resist and underlayer coating, development and plasma etch transfer to achieve best in class patterning performance. We will introduce new hardware and process innovations to address EUV stochastic issues, and present strategies that can extend into High NA EUV patterning. A strong focus will be placed on dose reduction opportunities, thin resist enablement and resist pattern collapse mitigation technologies. CAR and MOR performance for leading edge design rules will be showcased. As the first High NA EUV scanner is scheduled to be operational in 2023 in the joint high NA lab in Veldhoven, Tokyo Electron will collaborate closely with imec, ASML and our materials partners to accelerate High NA learning and support EUV roadmap extension.
Extreme ultraviolet (EUV) lithography has been used for mass production for several years. Now the resolution limit of current 0.33 NA single exposure has been approaching. To enhance the resolution limit, high NA exposure tool has been developing. At the limit, not only the stochastic failures1, but also patterning trade-off has been becoming challenging. In this paper, to overcome the patterning trade-off of LS and CH, several approaches were demonstrated for both CAR and MOR. As for chemically amplified resist (CAR), to overcome the patterning trade-off of line and space, two different approaches were demonstrated. One was a developer rinse process optimization, and the other was a top deposition treatment during etching process. By using the two approaches, pitch 24 nm LS patterns were successfully transferred. As to CAR CH patterning, a new shrink technique during etch process was successfully tested for sub 15 nm hole patterning. No missing hole detected at 12 nm hole size by voltage contrast metrology. For tighter nodes, spin-on metal oxide resist (MOR) have been considering to be used because it offers a series of advantages. It has high sensitivity and resolution because of its high photon absorption and simple reaction mechanism. It also inherently has a higher etch resistance which enables resist thickness thinner and collapse margin higher. Spin-on process of MOR is expect to contribute high productivity which is essential for high volume manufacturing (HVM). Because defect reduction is one of the key points to enable MOR process for HVM, continuous investigation of defect mitigation has been done. For pitch 32 nm LS, the mitigation was confirmed by fine optimization with the combination of the etch process and the implementation of new under layers. As to pitch 28nm line and space, optimized illumination gave better defect process windows. Moreover, a new wet developer process was successfully proposed to prevent pitch 36 nm hexagonal pillars collapse during wet development with 25% higher EUV sensitivity.
EUV (extreme ultraviolet) lithography is progressively being inserted in high volume manufacturing of semiconductors to keep up with node shrinkage. However, defectivity remains one big challenge to address in order to be able to exploit its full potential. As in any type of lithographic process, processing failures and in-film particles are contributors that need to be reduced by the optimization of coating and development processes and improved dispense systems. On top of these defects, stochastic failures, due to photon shot noise or non-uniformities in the resist, are another major contribution to the defectivity. To support their mitigation, etch process can be used to avoid their transfer to underlying layers. However, it requires a sufficient resist mask thickness. For line and space patterns, providing more resist budget comes with a trade-off which is the increase of pattern collapse failures, especially with shrinking critical dimensions. Collapse mitigation approaches are therefore very important to enable tight pitches and were explored. Stack engineering and especially optimization of resist under layers will be crucial components to enable patterning and defect reduction of shrinking pitches. Finally, as an alternative to traditional chemically amplified resists, metal containing resists are also promising because of their inherent high etch resistance. Dedicated hardware and processes were developed the use of such materials and prevent metal contamination to other tools during further processing steps.
In this report will be presented the latest solutions to further decrease defectivity towards manufacturable levels and provide more process margin to achieve better quality patterning towards the limits of NA 0.33 EUV exposure. Furthermore, technologies to improve CD uniformity and stability, which are required for mass production, will also be reported.
The enhancement in chemical gradients between the EUV exposed and unexposed areas can generate a wider process window, possibly, a smaller stochastic defectivity, and a lower local CD uniformity in EUV resists. This enhancement, in turn, helps to overcome the challenge of the small process window in high NA EUV lithography. In this work, a new concept resist, which is developed based on our chemical gradient enhancement technique model, is used to drive the chemical gradient upward chemically. The resist also has the capability of absorbing UV selectively at EUV exposed areas. Therefore, the UV flood exposure system, which has been discussed in Photosensitized Chemically Amplified ResistTM (PSCARTM), is used as another key part to further enhance the new resist. The new concept resist with UV lights was confirmed to give 15.1% improvement in its EUV sensitivity and, simultaneously, 25.0% improvement in local CD uniformity. This technique might be one of the solutions to bring CAR resist further into high-NA EUV lithography.
Flood Exposure Assisted Chemical Gradient Enhancement Technology (FACET) is introduced for improvement in EUV resist resolution, process control, roughness, patterning failure and sensitivity. Experimental EUV exposure latitude was enhanced (~1.5 times) with FACET using the assist of UV flood exposure. The mechanism of the process window improvement by FACET is explained by non-linear resist coloring (enhancement of UV absorption) vs. EUV exposure dose to enhance acid image contrast during UV flood exposure. To balance chemical gradient enhancement and stochastic effects, Stochastic Aware Resist Formulation and Process optimizer (SARF-Pro) with a fast stochastic simulation model is created. SARF-Pro predicts stochastic patterning failure risks, and optimizes resist formulation and processes by putting emphasis on stochastic variation across patterns. Photosensitized Chemically Amplified ResistTM (PSCARTM) 2.0 with FACET and standard chemically amplified resist (CAR) optimized in SARF-Pro suggests that PSCAR 2.0 with FACET has the potential of better process window, roughness, sensitivity and, we hypothesize, reduced risk of stochastic defects compared with standard CAR.
Resist Formulation Optimizer (RFO) is created to optimize resist formulation under EUV stochastic effects. Photosensitized Chemically Amplified ResistTM (PSCARTM) 2.0 reaction steps are included in the resist reaction model in RFO in addition to standard Chemically Amplified Resists (CAR) reaction steps. A simplified resist roughness calculation method is introduced in RFO. RFO uses “fast stochastic resist model” which uses continuous model information for stochastic calculation. “Resist component’s dissolution inhibition model” is also introduced for better prediction of different resist formulations in RFO. The resist component’s dissolution inhibition model is used for calculation of both Dissolution Inhibition Slope (DIS) and Dissolution Inhibition Deviation (DID). By dividing DID by DIS at a pattern edge, Line Edge Roughness (LER) can be predicted. The RFO performance is validated to give low residual errors after calibration even for different resist formulations. RFO is designed to optimize the resist formulation to minimize resist roughness as a cost function with keeping target CD. RFO suggests that PSCAR 2.0 with Polarity Switching photosensitizer precursor (POLAS) in combination with photosensitizer (PS) image enhancement may provide reduced resist roughness. Simulations using a calibrated rigorous stochastic resist model for S-Litho show a good prediction of PSCAR 2.0 process performance.
Photosensitized Chemically Amplified ResistTM (PSCARTM) has been demonstrated as a promising solution for a high sensitivity resist in EUV lithography mass production. This paper describes the successful calibration of a PSCAR resist model for deployment within rigorous lithography process simulation, capturing continuum as well as stochastic effects. Verification of the calibrated model parameters was performed with new patterns or with new resist formulations with good agreement. The reduction of required EUV dose of PSCAR resist while maintaining similar roughness levels have been achieved both from experimental result and from simulated result. The simulation of PSCAR continues to be a great tool for understanding, predicting, and optimizing the process of PSCAR.
In EUV lithography (EUVL), the most critical issue has been low intensity of the EUV light source. Light-source intensity and resist sensitivity have a complementary relationship. Therefore, the sensitization of EUV resist is very important to compensate the low intensity of the EUV light source. However, dramatically improving the resist sensitivity of chemically amplified resist (CAR) is very difficult because of the resolution/line-width roughness/sensitivity (RLS) trade-off. Therefore, we propose a very new process: high resist sensitization by the combination lithography of EUV or EB pattern exposure with UV flood exposure (PF combination lithography) of photosensitized chemically amplified resist (PS-CAR). The combination lithography of EB pattern exposure with UV flood exposure achieved a sensitivity enhancement of more than a factor of 10 with respect to conventional EB single-exposure lithography, without loss in space resolution of line/space of 75 nm1. The breakthrough of RLS trade-off by PF combination lithography of PS-CAR is explained based on RLS trade-off simulation method2 and acid generation mechanism of PF combination lithography of PS-CAR. One of the problems of the PF combination lithography of PS-CAR is postexposure delay (PED) effects suffered from airborne contamination. The present paper describes forming of 75 nm contact hole and PED effects in the PF combination lithography of PS-CAR. The sensitization of EUV resists by new method accelerates EUVL implementation.
Recently, polymer-bound PAGs (anion bound) are actively investigated as Extreme ultra violet (EUV) resist. Some
experimental results showed, in case of shot diffusion length acid generator bounded polymer showed lower sensitivity comparing with long diffusion length acid generator. In our previous investigation, short diffusion length PAG reactivity is changed due to binding to polymer by pulse radiolysis method. However, shot diffusion PAG bound to polymer showed lower LWR than long diffusion length PAG. Therefore, acid diffusion length difference originate in
PAG is important to resist performance. The diffusion length difference influence deprotection reaction in PEB process.
In this paper, we evaluated polymer-bound PAGs and polymer blend PAGs by electron beam (EB) exposure tool employing various PEB temperature and PEB time to conform the influence of acid diffusion regulation about polymer-bound PAGs for resist performances. As the result, even if acid generator bound polymer applied as a resist, acid diffusion regulation isn’t so strict that acid can migrate in the polymer matrix during PEB.
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